TOPCon Solar Cell Sidewall Texturing for Leakage Suppression

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Solution Overview

Problem

The manufacturing of tunnel oxide passivated contact (TOPCon) cells is hindered by leakage on lateral surfaces due to doping processes, which reduces solar cell efficiency.

Innovation Solution

The formation of pyramid base shaped textured structures on the lateral surfaces with specific side length and height differences relative to the second surface, combined with a polysilicon doped conductive layer and passivated contact layer, to prevent leakage channels by etching away doping elements on the lateral surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If doping processes are applied on front and back surfaces of TOPCon cells to improve conductivity, then electrical performance is improved, but leakage on lateral surfaces occurs which reduces solar cell efficiency

Engineering Contradiction:
Improveelectrical performanceVSAvoidleakage on lateral surfaces
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies different surface treatments to different locations: the front and back surfaces receive doping processes for conductivity, while the lateral surfaces receive etching treatment to remove doping elements and prevent leakage. This localized differentiation resolves the contradiction by allowing conductivity improvement where needed while preventing harmful leakage where it occurs.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent segments the surface treatment process into distinct steps: first applying doping to front and back surfaces, then selectively etching the lateral surfaces to remove doping elements. This segmentation allows the beneficial doping effect on main surfaces while eliminating the harmful leakage effect on lateral surfaces.

Inventive Principle:
Principle #1Segmentation

2Productivity

If etching is performed to remove doping elements on lateral surfaces to prevent leakage, then efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:
Improvesolar cell efficiencyVSAvoidmanufacturing process complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent performs the etching treatment on lateral surfaces as a preliminary step before applying the passivated contact layer. This preliminary action ensures that doping elements are removed from lateral surfaces beforehand, preventing leakage channels from forming during subsequent processing, while integrating smoothly into the existing manufacturing flow.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent controls the etching process parameters (etching solution concentration, temperature, time) to achieve selective removal of doping elements from lateral surfaces without excessive etching that would damage the structure. This precise parameter control enables the leakage prevention function while keeping the process manageable and integrated into standard manufacturing.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances solar cell efficiency by minimizing leakage channels and improving current collection, resulting in reduced reverse current and increased efficiency.

Implementation Method 1

a plurality of pyramid base shaped textured structures being constructed on the second surface and each of the lateral surfaces

Methodology Applied
Scientific EffectLight scattering: Scattering

Implementation Method 2

a passivated contact layer including a polysilicon doped conductive layer, the passivated contact layer being arranged on the second surface

Methodology Applied
Scientific EffectSurface passivation:

Implementation Method 3

there are doping processes on front and back surfaces of the cells

Methodology Applied
Scientific EffectDoping: Dopants

Data Source

PatentUS20250393339A1Solar cell and manufacturing method thereof, photovoltaic module, and photovoltaic system
Publication Date: 2025.12.25 TRINA SOLAR CO LTD
  • US20250393339A1 patent drawing
  • US20250393339A1 patent drawing
  • US20250393339A1 patent drawing

AI summary

A solar cell includes: a substrate including a first surface and a second surface arranged opposite to each other and a plurality of lateral surfaces adjacent to and located between the first surface and the second surface; a plurality of pyramid base shaped textured structures being constructed on the second surface and each of the lateral surfaces, wherein a minimum side length of each of top surfaces of the pyramid base shaped textured structures arranged on the lateral surfaces is L1, a maximum side length of each of top surfaces of the pyramid base shaped textured structures arranged on the second surface is L2, and L1>L2; a doped conductive layer arranged on the first surface; and a passivated contact layer including a polysilicon doped conductive layer, the passivated contact layer being arranged on the second surface.